Reducing Composite Defects in Blade Manufacturing

#WindWebinar

Reducing Composite Defects in Blade Manufacturing

#WindWebinar

q  This webinar will be available afterwards at www.windpowerengineering.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar

Before We Start

#WindWebinar

Paul Dvorak Editorial Director - Moderator

Windpower Engineering & Development

Santhosh Chandrabalan Technical Business Development

Leader – Wind Energy 3M Wind Energy


Featured Speaker…

3M Deutschland GmbH

4 3 November 2015 . All Rights Reserved. © 3M

3 November 2015 . All Rights Reserved. © 3M

Dry Lay Up Adhsive 2.0

Effective Innovation

SanthoshKChandrabalan3MRenewableEnergyDivision

3M Deutschland GmbH


3M Deutschland GmbH


3M Renewable Energy Division – Wind Energy

§  3M enabling more efficient and reliable Wind Turbine Rotor Blades produced and maintained faster and safer

§  Leveraging 3M’s core competencies in the field of films, adhesives, tapes, coatings and the inventive power of 40+ additional corporate technology platforms

Bi Biotech Ce Ceramics Dd Drug Delivery Di Display Do Dental & Orthodontic Materials

Ec Energy Components

Em Electronic Materials

Fc Flexible Converting & Packaging

Fe Flexible Electronics

Fs Filtration, Separation, Purification

Fi Films

Im

Imaging

Fl Fluoromaterials

In Inspection & Measurement

Is Integrated Systems Design Lm

Light

Management

Md Medical Data Management

Me Metal Matrix Composites

Mf Mechanical Fasteners

Mi Microbial Detection & Control

Mo Molding

Mr Microreplication

Pe Predictive Engineering & Modeling

Nt Nanotechnology

Nw Nonwoven Materials

Rp Radiation Processing

Se Sensors

Po Porous Materials & Membranes

Pm Polymer Melt Processing

Wo Wound Management

Vp Vapor Processing

Su Surface Modification

Sm Specialty Materials

Op Optoelectronics

Pd Particle & Dispersion Processing

Pr Process Design & Control

Pp Precision Processing

Tt Track and Trace

We Accelerated Weathering

Ab Abrasives Ac Acoustics Ad Adhesives Am Advanced Materials An Analytical

As Application Software

3M Deutschland GmbH


Innovative Solutions for the Wind Industry

Rotorblade Surface

Rotorblade Structure

Rotorblade Process

Vortex Generators Aerodynamic Optimization of Installed Wind Turbines with customized enhancement

solutions

BladeBondingAdhesiveofferinglongpotlifeands=ll50%fastercure-addi=onallyincreasingcrackresistance/fa=gue

behaviour DryLayupAdhesiveRedcoloredsprayadhesivetoefficientlyfixthefibermatsduringdrylayup

ErosionProtec9onSolu9onsTapesandnewcoa=ngofferingbest-in-classerosionresistanceandinteres=ngprocess-related

advantagesinthebladeproduc=on

§ Reducecycle=me§ Lowerbladecosts§ Faster,efficientbladethroughput

§ Increasestrength§ Decreaseweight§ Lowerbladecosts§ Reducecycle=me§ Enhancemechanicalproper=es§ Improvelaminatequality

§ Improveresistancetoerosion§ An=-IcingandAn=-Fouling§ Reducecycle=me§ Improveaerodynamics§ Reduceinterferencewithradar§ Easiertomaintain

NanoMatrixResinInnova=veresins

significantlyincreasingmanymechanical

proper=esincludingcompressionstrengthof

CFRPsparcaps

WindRepairFillersEasyandfasttoapplyfillerofferingsignificant=mesavingsbefore

sanding

3M Deutschland GmbH


3M™ W7900 – Revolutionary composite spray adhesive Problem §  Holding fiberglass on vertical surface is a challenge in the wind blade lay up process §  Traditional method to tack fiberglass layers is very time consuming §  Traditional method to tack layers of fiberglass is labor intensive and operator dependent §  Fiberglass movement can cause wrinkles and waves in the final laminate §  Need to be an EHS safe solution §  Need a visual control without sacrificing end part quality §  Not to have minimum intrusion to Composite Mechanical properties Features §  Meeting most stringent EHS regulations (Meet's California's EHS Requirements)

§  Non particle based sprayable system – Less hindrance on mechanical properties

§  Fast tacking with a long work time range from 15 seconds to 30 minutes

§  Green color providing visual application control

§  Innovative color changing feature has little to no effect on final visual part quality

§  Robotic application possible

Advantages §  Reduce the amount of time required for dry layup

§  Reduce wrinkles, which can be source of major failures

3M Deutschland GmbH


Fiber Glass Lay Up Aids

Past

Present - Spray

Future – DLUA 2.0

4X Application

Past - Spray

DLUA

Green to Clear w Epoxy

3M Deutschland GmbH


DLUA 2.0 Product Overview

3M Deutschland GmbH


W7900 Color Changing Effect – In Infusion

Visual Application Control

No Impact on Final Part Appearance

3M Deutschland GmbH


Standard Spray Adhesives vs DLUA 2.0 3M DLUA 2.0 Standard Particle Spray

§ Particle based bonding § Red color § Minimum intrusion to infusion § Minimum effect on Composites

mechanical § Designed to provide process and

quality benefits

§ Chemical bonding § Green to clear § Little to no intrusion to the infusion

process § Expected to have least effect on

Composites mechanical § Designed to provide process and

quality benefits combined with final aesthetics

Standard Lace Spray

§ Contact adhesive – Designed to bond to itself

§ Higher product concentration needed for adequate bonding

§  Intrusive for infusion process due to lace patterns

§ Residual stress and loss in mechanical properties due to lace pattern

3M Deutschland GmbH


** Per John Mandell and David Miller, PhD, the delamination load is approximately proportional to the square root of the delamination energy values, GIC & GIIC * As per MSU Testing

Property Control DLUA Typical

Application Level (2010)

DLUA 2.0 Typical Application Level

(2015) 0 g/m2 ~ 0.5 g/ft2 ~ 0.5 g/ft2

Fatigue --- No change No change

Tensile Strength - Longitudinal --- No change No change

Tensile Strength - Transverse --- No change No change

Compression Strength - Longitudinal --- No change No change

Compression Strength - Transverse --- No change No change

Short Beam Shear Strength --- -15% No change ENF Mode II Fracture Toughness Energy, GIIC Approximate ENF Load, GIIC

1/2** --- -15% -8%

No change No change

DCB Mode I Fracture Toughness, GIC Approximate DCB Load, GIIC

1/2** --- No change No change

No change No change

DLUA vs DLUA 2.0 – Recommended Level (Montana State University)

No change on final composite properties*

3M Deutschland GmbH


** Per John Mandell and David Miller, PhD, the delamination load is approximately proportional to the square root of the delamination energy values, GIC & GIIC * As per MSU testing

Property Control DLUA Over Application

(2010)

DLUA 2.0 Over Application

(2015) 0 g/m2 15.0 g/m2 15.0 g/m2

Fatigue --- No change No change

Tensile Strength - Longitudinal --- No change No change

Tensile Strength - Transverse --- No change No change

Compression Strength - Longitudinal --- No change No change

Compression Strength - Transverse --- No change No change

Short Beam Shear Strength --- -40% -25% ENF Mode II Fracture Toughness Energy, GIIC Approximate ENF Load, GIIC

1/2** --- -37% -20%

-24% -13%

DCB Mode I Fracture Toughness, GIC Approximate DCB Load, GIIC

1/2** --- No change No change

No change No change

DLUA vs DLUA 2.0 – 3X Application (Montana State University)

Minimum effect on final laminate even at 3X application*

3M Deutschland GmbH


Standard Spray Adhesives vs DLUA 2.0 – “Nozzle Plugging”

§  Clogged traditional spray adhesives à cleaning of nozzle required §  No clogged nozzle of green spray can (DLUA 2.0)

3M Deutschland GmbH


3M™ DLUA vs DLUA 2.0 – Higher Shear and Peel

Provides higher Shear & Peel Properties to hold the reinforcement in place with single (one side)

application

Shear

Peel

3M Deutschland GmbH


DLUA 2.0 EHS Overview § Newly developed product with a unique formulation from other 3M spray

adhesives § DLUA 2.0 and standard spray systems are completely different (Both in

formulation and bonding mechanism) § Differences in formula vs. standard spray

― Different solvent systems: DLUA 2.0 is acetone/ cyclohexane based and standard spray systems are dimethyl ether/ methyl acetate/ cyclohexane based

― W7900 has a green dye so it will be visible when you use it. Therefore, you can accurately use the correct amount

― With <25% VOC, its the only formulation that is accepted by most stringent EHS regulations (California Regulations)

3M Deutschland GmbH


Innovative

Color Change

Better EHS <25% VOC**

Better Composite Properties No Impact on Mechanical Properties*

Robust Improved

Sprayability

DLUA 2.0 – In Summary

*when applied at recommended levels as per Montana State University testing **in accordance to US EHS regulations

3M Deutschland GmbH


Making progress possible

SanthoshKrishnaChandrabalanTechnicalBusinessDevelopmentLeaderWindEnergy-RenewableEnergyDivisionE-Mail:[email protected]:651-230-5043www.3M.com/wind

#WindWebinar

Paul Dvorak Editorial Director - Moderator Windpower Engineering & Development

Santhosh Chandrabalan Technical Business Development 3M Wind Energy [email protected]


Questions?

@Windpower_Eng

#WindWebinar

Thank You q  This webinar will be available at

www.windpowerengineering.com & email

q  Tweet with hashtag #WindWebinar

q  Connect with Windpower Engineering & Development

q  Discuss this on EngineeringExchange.com

Reducing Composite Defects in Blade Manufacturing

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Transcript of Reducing Composite Defects in Blade Manufacturing